Refrigerator evaporator and method of manufacturing the same as

ABSTRACT

Disclosed an integrated refrigerator evaporator having a plurality of pipes and fins which is manufactured by injection molding with plastics. According to the present invention, pipes and fins are molded by means of at least one plastic plates, and a heat exchanger is formed by molding the pipes and fins in a series of “S” shape. A first bending section formed by the heat exchanger, which is molded in a series of “S” shape, is inserted into a mold main body to manufacture a header cap. A first header cap is manufactured by injecting melted plastic material body into the mold main body under the state of covering a mold cap. The first header cap is engaged with a first header main body comprising the first header cap and the refrigerant inlet and outlet. The refrigerator evaporator according to the present invention results in a relatively lower product cost than the evaporator composed of a metal substance as well as a high recyclability.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The present invention relates to a refrigerator evaporator, and more particularly to a refrigerator evaporator and method of manufacturing a refrigerator evaporator of both a more improved structure and manufacturing process than the conventional one using plastic materials.

[0003] 2. Description of the Prior Art

[0004] In general, the refrigerator as an appliance for storing and keeping stuff such as food under low temperatures roughly consists of a storage compartment and a cooling compartment. This type of a refrigerator can be classified into four kinds according to the cooling methods: an ice refrigerator, in which a lump of ice is put on an upper part of the storage compartment to cool down inside thereof; an electric refrigerator, in which gaseous Freon is condensed and transferred to a condenser to be liquefied by discharging heat; a gas refrigerator employing an absorption freezer, which uses ammonia aqueous solution as a refrigerant; and an electronic refrigerator utilizing a Peltier element for the purposes of both cooling and heating the food according to the direction of electric current.

[0005] An evaporator is essential to any types of refrigerator, regardless of the kinds of refrigerant to be used, for exchanging latent heat with existent heat by means of evaporation of the refrigerant. Such a conventional refrigerator evaporator has been manufactured by utilizing metals such as copper or aluminum in consideration of the problems in heat exchanging efficiency and pressure endurance, etc. The following is an explanation of the method of manufacturing the conventional refrigerator evaporator made with reference to the accompanying drawings FIGS. 1A and 1B.

[0006] Referring to FIGS. 1A and 1B, refrigerant pipes 1 a, 1 b are first extruded by means of metal (e.g., cooper, aluminum, etc.). Fins 2 a, 2 b are then manufactured by molding a metal panel.

[0007] Metal refrigerant pipes 1 a, 1 b are inserted into the fins 2 a and 2 b and elongated to a desired length. The metal refrigerant pipes 1 a, 1 b are mechanically engaged with the fins 2 a, 2 b.

[0008] The body incorporating the refrigerant pipes 1 a, 1 b into the fins 2 a, 2 b is bent in a series of “S” shape or in the shape of a serpent to be completed as a heat exchanger.

[0009] However, since most of the refrigerator evaporators including the ones described above are composed of metal of high thermal conductivity and strength, there are some problems.

[0010] First, employing metal substance results in a relatively high material cost of the refrigerator evaporator, thereby elevating the cost of a refrigerator including a heat exchanger.

[0011] Second, employing a metal substance also requires a more complicated manufacturing process than employing a non-metal substance, thereby resulting in a high processing cost. Further, the high weight of the metal evaporator causes a problem in transportation.

[0012] Third, employing a metal substance lowers recyclability and durability of the product.

[0013] Fourth, employing a metal substance impedes modification of the design of the product.

SUMMARY OF THE INVENTION

[0014] To resolve the conventional problem described above, an object of the present invention is to provide a refrigerator evaporator having a plurality of pipes and fins which is manufactured by injection molding with plastics. To accomplish the object, the refrigerator evaporator according to the present invention comprises a heat exchanger having a plurality of pipes for circulating a refrigerant and a plurality of fins molded in a series of “S” shape for mechanically engaging the plurality of pipes; a first header positioned at a first bending section formed by the heat exchanger molded in a series of “S” shape and having an inlet and an outlet for a refrigerant; and a second header engaged with a second bending section positioned corresponding to the first header, characterized in that the heat exchanger, first header and second header are integrated in plastics. The first header preferably comprises more than one inlet tanks, an outlet tank, a return tank, and a bracket for preventing distortion of the heat exchanger.

[0015] The method of manufacturing the refrigerator evaporator to achieve an object of the present invention comprises the steps of: forming a heat exchanger by molding pipes and fins with a plastic panel and molding the pipes and fins in a series of “S” shape; inserting the first bending section formed by molding the heat exchanger in a series of “S” shape into a mold body for forming a header cap; manufacturing a first header cap by injecting melted plastic material into the mold main body under the state of covering the molding cap; and engaging the first header cap with the main body of the first header having a molded inlet and an outlet of the refrigerant.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016]FIGS. 1A and 1B are a perspective view and a cross-sectional view illustrating the pipes and fins used in the conventional refrigerator evaporator.

[0017]FIG. 2 is a three-dimensional section view of the refrigerator evaporator according to one embodiment of the present invention.

[0018]FIG. 3 is a detailed cross-sectional view illustrating the header.

[0019]FIG. 4 is a view illustrating the manufacturing steps of a header of the refrigerator evaporator shown in FIG. 2.

[0020]FIG. 5 is a cross-sectional view of the refrigerator evaporator according to another embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0021] The following is a detailed description of the preferred embodiment of the present invention made with reference to the accompanying drawings.

[0022]FIG. 2 is a cubic sectional view of the refrigerator evaporator according to an embodiment of the present invention.

[0023] Referring to FIG. 2, the refrigerator evaporator according to the present invention comprises a heat exchanger 17 formed by molding a heat exchange plate 13, which consists of a plurality of fins mechanically engaging a plurality of pipes for circulating a refrigerant, in a series of “S” shape; a first header 15 positioned at a first bending section of the heat exchanger 17 and having an inlet 22 and an outlet 21 for the refrigerant; and a second header 16 engaged with the second bending section of the heat exchanger 17 to be positioned to correspond to the first header 15. The heat exchanger 17, the first header 15 and the second header 16 are preferably extrusion-molded or injection-molded with integrated plastics.

[0024]FIG. 3 is a detailed sectional view of the header shown in FIG. 2. Referring to FIG. 3, the first header 15 comprises a header tank 23 divided into an inlet tank 19 and an outlet tank 18 by a separating plate 20, a bracket 24 for preventing distortion of the heat exchanger 17, and a return tank 25.

[0025] The following is a detailed description of the manufacturing process of a refrigerator evaporator according to the present invention made with reference to the accompanying drawings.

[0026] A plastic heat exchanging plate 13 consisting of a plurality of pipes and fins is manufactured by extrusion or injection.

[0027] The heat exchanging plate 13 is repeatedly bent in a series of “S” shape or in the shape of a serpent. At this stage, two bending sections are formed as shown in FIG. 2. Of the bending sections of the molded heat exchange section 14, the first bending section, at which the beginning and end portions of the pipes are positioned, is engaged with the first header 15 of plastic material. The second header 16 (or a bracket) of the plastic material is mounted on the opposite side of the first bending section.

[0028] Accordingly, a refrigerant may flow through the pipes of the extruded heat exchange section 14. Since the air passes through the inside and outside of the heat exchange section 14, a heat exchange between the refrigerant and air is automatically performed.

[0029] The first header 15 roughly comprises a header main body 30 and a header cap 38 as shown in FIG. 3. The header main body 30 further comprises a header tank 23 consisting of an inlet tank 31 and an outlet tank 32, a bracket 24 for preventing distortion of the heat exchange section 14, which is bent in the shape of a serpent, and a return tank 25. A refrigerant inlet pipe 34 and a refrigerant outlet pipe 35 are extrusion-molded, respectively, in the inlet tank 31 and the outlet tank 32. The inlet tank 31 is distinguished from the outlet tank 32 by a separating plate 20.

[0030] Since the header of the refrigerator evaporator according to the present invention is manufactured by the following process, no additional work is required for airtight between the header cap 38 and the heat exchange plate 13. In other words, manufacture of the header cap 38 is completed by injecting melted plastic material into the mold main body 41 under the state of covering the mold cap 42 as shown in FIG. 4. Manufacture of the first header 15 is completed by engaging the header cap 38 with the header main body 30. As a consequence, airtight can be maintained between the header cap 38 and the heat exchange plate 13.

[0031] The second header 16 is extruded by the same process as above for manufacturing the first header 15 except that the refrigerant inlet 34 and outlet 35 are not molded because of any necessity. In other words, the second bending section of the pre-manufactured 25 integrated plastic heat exchange plate 13 is injected into the mold main body 41, and melted plastic material is inserted into the mold main body 41 under the state of covering the mold cap 42 to complete the header cap of the second header 16. Subsequently, the header cap is engaged with the header main body (not illustrated in the drawings) to complete the second header.

[0032]FIG. 5 is a cross-sectional view of the refrigerator evaporator according to another embodiment of the present invention. FIG. 5 shows formation of a plurality of return tanks 61-65 in the header main body 50 by suitably forming a plurality of separating plates 71-75 inside of the header tank and the return tank. Accordingly, a refrigerator evaporator enable to change the flow channels of commerce of the refrigerant is provided through this process.

[0033] According to a preferred embodiment of the present invention, manufacture of a heat exchanger with an integrated plastic plate serves to drastically reduce the cost of manufacturing a refrigerator evaporator, which is conventionally composed of metal substance. A simulation of the present invention proved that about 47% of the material cost and about 53% of the manufacturing cost of the heat exchanger according to the present invention could be saved in comparison with the aluminum heat exchanger.

[0034] Furthermore, the environment-friendly refrigerator evaporator according to the present invention also serves to protect environment owing to its notable recyclability, and has a merit of long durability due to non-corrosion. Modification of any layouts of the refrigerator evaporator according to the present invention is also easier than the refrigerator evaporator composed of a metal substance. 

What is claimed is:
 1. A refrigerator evaporator, comprising: a heat exchanger having a plurality of pipes for circulating a refrigerant and a plurality of fins molded in a series of “S” shape for mechanically engaging the plurality of pipes; a first header positioned at a first bending section formed by the heat exchanger molded in a series of “S” shape and having an inlet and an outlet for a refrigerant; and a second header engaged with a second bending section positioned corresponding to the first header, characterized in that said heat exchanger, first header and second header are integrated in plastics.
 2. The refrigerator evaporator of claim 1 , wherein said first header comprises a plurality of inlet tanks, outlet tanks, return tanks and brackets for preventing distortion of said heat exchanger.
 3. The refrigerator evaporator of claim 2 , wherein said inlet tanks and outlet tanks are integrated tanks divided by at least one separating plate.
 4. The refrigerator evaporator of claim 2 , wherein a refrigerant inlet is formed at said inlet tank, and a refrigerant outlet is formed at said outlet tank.
 5. A method of manufacturing a refrigerator evaporator, comprising the steps of: forming pipes and fins by means of a plastic plate, and manufacturing a heat exchanger by molding said pipes and fins in a series of “S” shape; manufacturing a first header cap by inserting a first bending section, which is formed by said heat exchanger molded in a series of “S” shape, into a mold main body for manufacturing a header cap, and by injecting melted plastic material into said mold main body under the state of covering the mold cap; and engaging said first header cap with said first header main body having said refrigerant inlet and outlet.
 6. The method of claim 5 , further comprising the steps of: manufacturing a second header cap by inserting a second bending section of said heat exchanger into said mold main body for manufacturing said first header cap, and by injecting said plastic melting body into said melted plastic material under the state of covering the mold cap; and engaging said second header cap with said second header main body. 